Production system for producing formulations

ABSTRACT

The present invention relates to a production system for manufacturing of formulations, comprising a unit (1). The unit (1) includes a subunit (1.1) which includes a combination of a process mixer and a buffer tank, means of feeding defined amounts of feedstocks into the process mixer, a measurement unit for ascertaining properties of a part-batch of a formulation manufactured in the process mixer, an evaluation unit for determining a deviation of properties of the part-batches manufactured in the process mixer from the properties of a predefined target state, and a unit for adjusting the feed of feedstocks in view of the deviations. The present invention also relates to a process for manufacturing formulations.

The present invention relates to a novel production system formanufacture of formulations. The present invention additionally relatesto a process for manufacture of formulations, for example paints, whichis preferably conducted using the production system.

STATE OF THE ART

Formulations, i.e. multicomponent systems of greater or lessercomplexity, and the manufacture thereof are a central constituent in awide variety of different branches of industry. Examples include thepaints industry, the food and drink industry, or else the medicalindustry. Corresponding products (formulations) are manufactured byphysical mixing of liquid (free-flowing) and solid materials (rawmaterials) and/or of intermediates manufactured from corresponding rawmaterials beforehand.

Production systems and corresponding processes for manufacture offormulations are common knowledge. They typically contain one or moremixing vessels (process mixers) in which the components of the materialto be manufactured, after being weighed out, are mixed together.

The wide range of products (formulations) to be manufactured that existsin industrial production is frequently accompanied by a likewiseenormous complexity of raw materials and intermediates to be used (alsoreferred to collectively as feedstocks for production of products(formulations), where intermediates can also be referred to as aformulation, and so the term unless specified otherwise is considered tobe an umbrella term for products and intermediates).

It is also important that many raw materials, such as resins andadditives in particular, for example because some of the manufacturingprocesses therefor are complex, are not always supplied with completelyconstant properties and can then be used. The individual profiles ofproperties that then exist, in the case of use in the production offormulations, can lead to unforeseeable changes in the properties of thematerial produced. Thus, in general, a formulation is produced on thebasis of documented recipe specifications. If the actual state of thematerial manufactured which is to be determined then differs too farfrom the desired and fundamentally expected target state, it isnecessary to adjust the off-spec material.

An additional factor is that, even in modern production plants, theweighing or dosage of feedstocks is only possible with limited accuracy.Even slight changes, especially together with the above-describednon-constant profiles of properties of feedstocks, can lead todeviations in the properties of the material manufactured. Correspondingadjustments to the material manufactured are thus unavoidable.

The prior art solves this problem generally by the determination ofproperties of the material manufactured (actual state), thedetermination of the deviations of the actual state from the targetstate, and subsequent addition of one or more feedstocks to materialmanufactured for establishment of the target state.

A disadvantage of this form of adjustment is firstly that an adjustmentcan be made only by the addition of feedstocks. Adjustment in anacceptable manner is thus possible only in one direction. If, forexample, the viscosity of the material manufactured is too high,lowering of the viscosity is possible by the subsequent addition ofsolvents. Compensating for too low a viscosity by the addition of amultitude of resin components and additives, for example, in specificratios is impracticable.

A further disadvantage is the fact that the entire manufacturing processcomprising the actual batch manufacture and the only subsequentadjustment is very time-consuming.

Problem

The problem addressed by the present invention was that of providing aproduction system for manufacturing of formulations, which is able toovercome the above-described disadvantages and of improving theunavoidably necessary adjustment of material manufactured in the courseof industrial production processes in terms of process technology andtime.

Technical Solution

What has been found is a novel production system for manufacturing offormulations, comprising a unit (1) for the production of formulations,where the unit (1) comprises a subunit (1.1), comprising

-   -   a. at least one combination of a process mixer and a buffer        tank, where the process mixer and the buffer tank contain mixing        devices,    -   b. at least one connection between the process mixer and buffer        tank for transfer of part-batches of formulations manufactured        in the process mixer from the process mixer into the buffer        tank,    -   c. means (M) of feeding defined amounts of feedstocks into the        process mixer,    -   d. at least one measurement unit for ascertaining properties of        a part-batch of a formulation manufactured in the process mixer,    -   e. at least one evaluation unit which is in communication with        the measurement unit and is for determination of a deviation of        properties of part-batches manufactured in the process mixer        from the properties of a predefined target state,    -   f. at least one unit which is in communication with the        evaluation unit and is for adjusting the feed of defined amounts        of feedstocks into the process mixer, and which is set up to        take account of the deviations in the properties of a        manufactured part-batch from the properties of a predefined        target state and the number and size of further part-batches in        order to adjust the amounts of feedstocks fed in in the        manufacture of further part-batches.

What has also been found is a process for manufacturing formulations,comprising

-   -   feeding defined amounts of feedstocks into a process mixer in        which there is a mixing device for dispersion and mixing of        feedstocks,    -   manufacturing a part-batch of a formulation by mixing the        feedstocks in the process mixer,    -   transferring the part-batch into a buffer tank with mixing        device via a connection between process mixer and buffer tank,    -   ascertaining properties of the part-batch before, during or        after transfer into the buffer tank by means of a measurement        unit,    -   determining a deviation of properties of the part-batch from the        properties of a predefined target state by means of an        evaluation unit,    -   ascertaining the correction volumes for feedstocks that are        needed in view of the deviations in the properties of the        part-batch manufactured from the target state and the number and        size of further part-batches for establishment of the target        state of the overall batch,    -   manufacturing at least one further part-batch in the process        mixer, taking account of the correction volumes ascertained in        the manufacture of at least one of the further part-batches by        adjustment of the feeding of feedstocks into the process mixer,    -   transferring the at least one further part-batch into the buffer        tank,    -   combining the at least one further part-batch with the first        part-batch to manufacture the overall batch.

The production system of the invention and the process of the inventionenable the above-described disadvantages of the prior art to be overcomeand the necessary adjustment of formulations manufactured to be improvedin terms of process technology and time.

DESCRIPTION Production System

The production system of the invention comprises a unit (1) and/or asubunit (1.1).

According to the invention, the term “unit” or “subunit” describes thedelimitable properties and individual functions of the respective unitor subunit. It is not necessary, for example, for two units or subunitsto be spatially or physically clearly separated from one another and/orfor one subunit to constitute a spatially and/or physicallyindividualized region. For example, one subunit may have many differentregions. These regions may each be directly alongside one another or oneon top of another. Alternatively, they may equally be wholly or partlyspatially separated from one another, in which case, for example, otherregions, units or subunits of the production system are arranged incorresponding separation regions.

It is preferable that the subunit (1.1) is set up for manufacture ofliquid products (formulations). In addition, it is preferably suitablefor manufacture of any form of intermediates, especially liquidintermediates. This applies both to intermediates manufactured fromsolid and liquid raw materials and to intermediates manufactured fromliquid raw materials only. This equally applies to intermediates whichare manufactured from intermediates manufactured beforehand or fromintermediates manufactured beforehand and solid and/or liquid rawmaterials.

In this context, it is preferable that the subunit (1.1) is set up formanufacture of products and intermediates with exclusive use of liquidfeedstocks and/or feedstocks that can be used as liquid feedstocksthrough pretreatment. A corresponding pretreatment can take place, forexample, through shaking, stirring and/or tumbling, and also heating.

The person skilled in the art knows how the subunit (1.1) should be setup in this connection, and this is additionally also apparent from thedescription below (mixing devices for liquid feedstocks,fluid-conducting connections between process mixer and buffer tank,means (M) set up for feeding of defined amounts of liquid feedstocks).

In the context of the present invention, unless stated otherwise, theliquid (free-flowing) state relates in each case to a temperature of 20°C., standard pressure (1013.25 hPa) and a shear stress of 1000 s⁻¹ forone minute. If a component under these conditions has a viscosity of notmore than 10 000 mPas (measured, for example, with the Rheomat RM 180instrument from Mettler-Toledo), it is fundamentally referred to asliquid.

Feedstocks that can be used as liquid feedstocks through pretreatmentshould be understood as follows. It is of course possible, for example,to pretreat raw materials and intermediates which are to be used forproduction of products and which cannot be described as liquid under thefundamental conditions described above in such a way that they can beused as a liquid feedstock by the definition applicable here (viscosityof not more than 10 000 mPas).

It is more preferred that, in the subunit (1.1), clear and white liquidformulations (products and intermediates) are manufactured, preferablyexclusively clear and white liquid formulations. Very preferably,exclusively clear liquid formulations are manufactured. An example of aclear product is a clearcoat; an example of a clear intermediate is amixing varnish which is to be used at a later stage for manufacture ofproducts such as paints. An example of a white product is asolid-colored white basecoat.

The reason for this is that the plant design described in particular,with a combination of process mixer and buffer tank, can be cleanedquickly and efficiently without manual intervention by the CIP (cleaningin place) method which is known per se. In addition, optimal utilizationof the subunit (1.1) in conjunction with the subunit (1.2) describedbelow is possible in this way.

The subunit (1.1) comprises one or more combinations of at least twodifferent vessels, wherein the first vessel within such a combination isa process mixer and the second vessel is a buffer tank for mixturesdischarged from the process mixer, preferably liquid mixtures. Mixingdevices that are to be used therein, for example dissolvers, are knownto those skilled in the art. The mixing devices assure mixing offeedstocks and hence the manufacture of liquid formulations inparticular (process mixer), or the compositions manufactured can be keptin homogenized form for prevention of settling processes (buffer tank).The process mixer and buffer tank are connected to one another, suchthat mixtures manufactured in the process mixer, for exampleintermediates or products, can be discharged into the buffer tank in acontrolled manner. This is technically possible without any problem viacorresponding pipework, preferably fluid-conducting pipework, andintermediate connection of conveying means such as pumps and valves. Afurther mixing device, for example an inline dissolver, may also bearranged within the connecting unit between the process mixer and buffertank. This is advisable when the current contents in the process mixerare to be pumped in circulation in order to serve as a carrier streamfor further feedstocks which are to be fed to the production process. Inthat case, the further mixing device can serve to mix this carrierstream.

It is preferable that, within a combination, the buffer tank has agreater capacity than the process mixer. More preferably, the buffertank has at least twice the capacity compared to the process mixer,especially preferably at least three times the capacity. The processmixer here has, for example, a capacity of 0.1 to 60 tonnes, for example0.5 to 30 tonnes or else 1 to tonnes, or 2 to 5 tonnes.

The feeding of defined amounts of feedstocks into the process mixer viathe means (M) is effected in a manner known in principle to the personskilled in the art in this context.

For instance, transfer or withdrawal from corresponding reservoirs offeedstocks, for example tanks and other charge units known in thisrespect, is possible with incorporation of technical means of monitoringand closed-loop control of a mass flow of the particular feedstock.

For this purpose, the means (M) may comprise weighing units (for exampleweighing cells) and/or mass flow meters which can monitor and alsoregulate and adjust the flow, as a result of which it is firstlypossible to withdraw defined amounts from reservoirs of feedstocks.

In connection with liquid feedstocks, which are preferred, thedimensions of the particular mass flow meter here are dependent on theflows and the viscosity of the feedstocks. The flow (mass flow) isregulated, for example, by means of commonly available conveying means,for example pumps, the conveying output of which can be adjusted withina wide range, and/or a regulating valve which can affect the conveyingoutput via the throttling of the flow cross section. The exact locationof the individual elements, for example the regulating valves, in theoverall construction can be adapted to the individual case. They may,for example, be in the direct proximity of the conveying means, or elsein the direct proximity of collecting lines as mentioned further down.They can even be within a collecting line. The metering accuracy ofknown systems is at least 1%, based on the addition value. It is alsopossible to limit the metering rate to a target value.

In connection with solid feedstocks, which can likewise be used inprinciple, the mass flow can be regulated via the vibration of a coneand/or the driving of a screw. A vibration unit or the like (if neededto promote solid flow properties) may also be present. The meteringaccuracy of known systems is at least 2%, based on the addition value.It is also possible to limit the metering rate, for example, to onekilogram per second. In this case, the means (M) thus in any caseinclude means of determining a withdrawal volume (especially weighingcells). In addition, they include control means for the actualwithdrawal mechanisms (i.e., for example, cones or screws). The controlmeans would then be configured via an electronic control unit inparticular, which takes account of the information ascertained by theweighing cells to control the withdrawal mechanism and correspondinglyregulates and adjusts the withdrawal process with respect to therequirements.

Corresponding requirements for adjustment of the mass flow and hence theamounts of feedstocks fed in per unit time or overall can be obtainedunder electronic control via recipe specifications.

The means (M) are additionally set up for the feeding of the definedamounts of feedstocks into the process mixer. For this purpose, themeans (M) include, for example, pipework systems, especiallyfluid-conducting pipework systems, which transfer the defined amountsinto the process mixer.

In connection with liquid feedstocks, this preferably takes place withincorporation of collecting lines. This means that the feedstocks takenfrom reservoirs are first transferred via fluid-conducting pipeworksystems known per se into one or more collecting lines, via which theyare then fed to the process mixer.

The feedstocks can be fed in in an automated and electronicallycontrolled manner in any sequence (sequentially, in parallel, partly inparallel), in order, for example, to feed feedstocks which react withone another and/or are incompatible when in pure form or in highlyconcentrated form to the process mixer separately from one another. Itis also possible in this connection that the current contents of theprocess mixer are pumped in circulation via the collecting line andserve as a carrier stream for further feedstocks.

The feedstocks fed into the process mixer are then mixed by means of thecorresponding mixing devices.

The advantage of the described plant design of combinations of processmixers and buffer tanks is that particularly effective and exactmanufacture, adjustable within the process regime, of formulations andintermediates is possible in this way.

If, for example, a first part-batch of a material to be manufactured inthe process mixer has been manufactured on the basis of recipespecifications, especially in electronically documented form, this canbe transferred to the buffer tank. Depending on the properties of thefirst part-batch (actual state), the desired properties of the materialto be manufactured overall (target state) and the number of part-batchesto be manufactured overall and/or the size (mass, volume) of furtherpart-batches, controlled adjustment of the feeding of feedstocks in themanufacture of one or more further part-batches is possible. In thisway, it is especially possible to compensate for the variations inproperties, as described at the outset, of the feedstocks used, which,in the case of fixed use volumes, can lead to manufacture of a firstpart-batch having an actual state deviating from the target state.Further details in this regard are also described further down in thecontext of the process.

Accordingly, the subunit (1.1) additionally has a measurement unit forascertaining properties of a preferably liquid formulation or of a firstpart-batch of said formulation manufactured in the process mixer. Themeasurement unit may be assigned, for example, to the preferablyfluid-conducting pipework (connection) of the process mixer and buffertank. This means that it is possible by means of the pipework (or thecorresponding connecting conduit systems) to branch off liquid materialmanufactured and ultimately transfer it to a measurement unit. Thetransfer to the measurement unit may be automated or else manual. In themeasurement unit, in an automated or manually induced manner, variousproperties of liquid material can then be detected, for exampleviscosity, pH, conductivity, density, temperature. It is also possiblethat the measurement unit is arranged within the conduit system and thatanalysis takes place in an automated manner, for example by means of oneor more sensors for detection of properties of the liquid material.

The subunit (1.1) likewise comprises an evaluation unit which is incommunication with the measurement unit and is for determination of adeviation of properties of the material manufactured in the processmixer (actual state) and the corresponding properties of a predefinedtarget state. This evaluation too can be effected, for example, in anautomated manner by comparison of electronically transmitted propertydata of the actual state with electronically documented data of thetarget state (comparison of actual state with reference values).

The unit (1.1) not least comprises a specific apparatus for adjustmentof the feeding of feedstocks into the process mixer.

The unit for adjusting the feeding of feedstocks is connected to theevaluation unit, for example via an electronic information transferunit, and so can communicate therewith.

If a first manufactured part-batch has been analyzed with regard torelevant properties, these properties have been compared with a targetstate and the part-batch has been transferred into the buffer tank, themanufacture of one or more further part-batches can be conducted withadjustment of the feeding of feedstocks into the process mixer.Ultimately, it is then possible to obtain an on-spec material, i.e. amaterial displaying the target state within acceptable error limits.

For example, the deviations between the actual state of the firstpart-batch and the target state that have been detected by means of theevaluation unit can be used to make an adjustment in amounts offeedstocks fed in overall and/or per unit time to the process mixer inone or more further part-batches. If an excessively high proportion of afirst feedstock has been used in the context of the manufacture of thefirst part-batch, for example, the amount fed in is decreaseddisproportionately compared to the target state in one or more furtherpart-batches, in order to obtain an on-spec material overall. Theinverse procedure is correspondingly employed in the case of excessivelylow proportions of feedstocks.

The adjustment of the feeding of feedstocks can be made with automatedadjustment of the amounts of feedstocks taken from correspondingreservoirs via the means (M), and hence also adjustment of the feedinginto the process mixer. As already described above, the basic amount offeedstocks fed in can be controlled via regulation of the mass flow. Itis of course likewise possible to subject the mass flow of feedstocks toclosed-loop control and adjust it in this way. This is then effectedwith utilization of the information obtained from the evaluation unit.

Transfer of information from the evaluation unit is preferably effectedwith involvement of electronic information transfer units.

The unit for adjustment of the feeding of feedstocks is accordinglypreferably configured as an electronic control unit that processeselectronically transmitted property data from the evaluation unit,correlates it with further relevant input parameters, especially thenumber and size of part-batches to be manufactured, ascertainscorrection volumes of feedstocks and then electronically induces anadjustment of the feeding of feedstocks. It is of course necessary forthis purpose that the actual dosage mechanisms possessed by thetechnical means for closed-loop control and hence adjustment of the massflow (means (M)) are electronically addressable via the electroniccontrol unit.

It will be apparent from the above that the unit for adjustment of thefeeding of feedstocks, with regard to the actual adjustment, ispreferably adjusted such that, after the manufacture of all part-batches(i.e. the overall batch), the overall batch has the target state (i.e.is on-spec). What this means is that the corresponding correctionvolumes of feedstocks needed to establish the target state in theoverall batch are ascertained in the unit for adjustment, before thisthen induces a corresponding adjustment in the feeding of feedstocks.

The overall batches of formulations manufactured in the subunit (1.1)can then be dispensed in a manner known per se. For this purpose, chargeunits, for example delivery packaging, can be kept ready at appropriatepositions, which are filled from the buffer tank when required. Thedispensing can then be effected via incorporation of typical devicessuch as dispensing heads with dispensing probes, for example in adedicated dispensing unit of the production system which is provided forthe purpose.

Preferably, the subunit (1.1) additionally has an onward conduction unitfor onward conduction of formulations manufactured, namelyintermediates, to the preferably existing subunit (1.2) which isdescribed below. In this way, it is possible to use the respectiveintermediate in the subunit (1.2) for further production in a veryprocess-efficient manner and without intermediate dispensing orredispensing.

The unit (1) preferably comprises a further subunit (1.2) formanufacture of colored and/or effect-imparting formulations with use ofliquid feedstocks and/or feedstocks that can be used as liquidfeedstocks through pretreatment.

Corresponding formulations are especially paints containing coloringand/or effect pigments, for example solid-colored basecoats oreffect-imparting basecoats. Paints such as filler-surfacers whichgenerally contain white and/or black pigments are also in principle tobe included among the colored formulations. Useful feedstocks formanufacture of these formulations especially include color and/or effectpastes, and the intermediates (mixing varnishes) manufactured in subunit(1.1). It is of course additionally possible to use liquid rawmaterials.

The subunit (1.2) may comprise the devices that have already beendescribed above and are known in connection with the production offormulations, i.e. process mixers and mixing devices, for exampledissolvers for mixing and homogenization of the feedstocks in theprocess mixers. The feedstocks can then likewise in principle be fed inas described above, for example by means equivalent to theabove-described means (M). The formulations that are then complete canbe dispensed via known dispensing systems in disposable or reusabledelivery packaging and then, for example, transferred to a warehouse forlong-term storage or delivered directly to a customer.

A particularly preferred configuration of the subunit (1.2) is describedhereinafter.

In this embodiment, the unit (1.2) does not comprise, or does not justcomprise, the already described process mixers including mixing devices,in order thus ultimately to assure batchwise manufacture. Instead, theunit (1.2) comprises the means described hereinafter for continuousmanufacture of colored and/or effect-imparting formulations.

For this purpose, the unit (1.2) first comprises a small-volume processmixer (kP), including mixing device. The mixing devices are preferablyinline dissolvers, static mixers, or mixers working by the rotor-statorprinciple. The term “small-volume” relates here to a significantlysmaller capacity in relation to process mixers used on the industrialproduction scale (with a capacity usually of several tonnes). Theprocess mixer has, for example, a capacity of 0.1 to 100 liters, forexample 0.5 to 50 liters or else 1 to liters, especially 1 to 10 liters,for example 5 liters. The process mixer is set up such that the mixingdevice is arranged between the inlets for feeding of feedstocks and theat least one outlet for removal of formulations manufactured. Thefeedstocks flowing into the process mixer (kP) must thus pass throughthe mixing device before they exit from the process mixer. The smallmixing volume defined by the small size of the process mixer andcorresponding high energy inputs through the mixing device, efficientmixing of the feedstocks within the context of continuous manufacture offormulations is possible. “Continuous manufacture” is understood to meanthat the feedstocks for manufacture flow into the process mixer (kP) incontinuous, specifically adjustable mass flows and the feedstocks, inthe form of a mixture after passing through the mixing device, i.e. as aformulation, then leave the process mixer again via the outlet(s) in alikewise continuous mass flow. Typical outputs of the mixing devices,for example of a mixer working by the rotor-stator principle, are in therange from 1 to 250 kW, especially 5 to 200 kW, preferably 25 to 150 kW,more preferably 50 to 125 kW or else 85 to 95 kW, where the personskilled in the art is able to adjust the output without any problem tothe other characteristics of the process mixer (kP), for example thecapacity (low capacities correspond to comparatively lower outputs). Therotation speeds may vary according to the design, where typical rotationspeeds may be between 1000-10 000 rpm, especially 2000-6000 rpm or else3000-4000 rpm. Preferably, the process mixer is completely filled andhence free of air during the production, such that production ispossible without formation of foam.

The feedstocks are preferably fed in as follows. First of all,intermediates manufactured in the subunit (1.1), especially clearintermediates, are fed in as main flows, especially via fluid-conductingpipework with optional intermediate connection of conveying means suchas pumps and valves, directly from said subunit (1.1). Requirements foradjustment of the mass flow can be obtained under electronic control viarecipe specifications. Technical means of achieving a specific mass floware described above, more particularly in the case of the means (M)

In addition, color and/or effect pigments and functional fillers arepreferably introduced using intermediates manufactured beforehand, forexample color and/or effect pastes. Feedstocks of this kind can also besupplied via means similar or equivalent to the means (M) alreadydescribed. Corresponding requirements for adjustment of the mass flowand hence the amounts of feedstocks fed in per unit time or overall canbe obtained under electronic control via recipe specifications.

The mass flow discharged from the process mixer (kP) is then transferredvia fluid-conducting pipework into a buffer tank, including mixingdevices for prevention of settling processes. The buffer tank has, forexample, a capacity of 0.1 to 60 tonnes, for example 0.5 to 30 tonnes orelse 1 to 15 tonnes or 2 to 5 tonnes, and is replenished continuously bythe material discharged from the process mixer.

The advantage of the described plant design of combinations of processmixers and other tanks is that particularly effective and exactmanufacture, adjustable within the process regime, of formulations andintermediates is possible in this way, irrespective of batch size.

For example, continuous production of a batch of the material to bemanufactured by means of the process mixer (kP) on the basis of recipespecifications, especially in the form of electronic documentation, iscommenced. Depending on the properties of the material produced oncommencement of batch production (actual state), the desired propertiesof the material to be manufactured overall (target state) and the size(mass, volume) of the batch, controlled adjustment of the feeding offeedstocks in the manufacture is possible. In this way, it is possible,for example, to compensate for variations in properties of theintermediates used which, in the case of fixed mass flows, can lead tomanufacture of material having an actual state deviating from the targetstate. The comparatively large capacity of the buffer tank, to bealigned to the individual case, additionally ensures that the size ofthe batch can still be subsequently adjusted. This is an option, forexample, if the actual state of the material produced at the startdiffers particularly significantly from the target state. Furtherdetails in this regard are also described further down in the context ofthe process of the invention.

Preferably, the subunit (1.2), especially in conjunction with saidcombination of process mixer (kP) and buffer tank for continuousproduction, therefore has a measurement unit for ascertaining propertiesof a liquid formulation manufactured in the process mixer. Themeasurement unit may be assigned, for example, to the fluid-conductingpipework (connection) of the process mixer and buffer tank. This meansthat it is possible by means of the pipework (or the correspondingconnecting conduit systems) to branch off liquid material manufacturedand ultimately transfer it to a measurement unit. The transfer to themeasurement unit may be automated or else manual. In the measurementunit, in an automated or manually induced manner, various properties ofliquid material can then be detected, such as viscosity, pH, color,density, conductivity and temperature. It is also possible that themeasurement unit is arranged within the conduit system and that analysistakes place in an automated manner, for example by means of one or moresensors for detection of properties of the liquid material.

The subunit (1.2) likewise preferably comprises, especially inconjunction with said combination of process mixer (kP) and buffer tank,and the measurement unit, an evaluation unit which is in communicationwith the measurement unit and is for determination of a deviation ofproperties of the material manufactured in the process mixer (actualstate) and the corresponding properties of a predefined target state.This evaluation too can be effected, for example, in an automated manner(comparison of actual state with reference values).

The unit (1.2) not least preferably comprises, especially in conjunctionwith said combination of process mixer (kP) and buffer tank, themeasurement unit and the evaluation unit communicating with themeasurement unit, a specific apparatus for adjustment of the feeding offeedstocks into the process mixer.

The unit for adjusting the feeding of feedstocks is connected to theevaluation unit, for example via an electronic information transferunit, and so can communicate therewith.

If, for example, at the start of continuous batch production, thematerial manufactured has been analyzed with respect to relevantproperties and these properties have been compared with a target state,it is possible to conduct the further continuous manufacture withadjustment of the feeding of feedstocks into the process mixer. It isadvantageous here to regularly analyze the properties of the materialproduced at specific time intervals or continuously and compare themwith the target state in order thus to enable iterative adjustment ofthe feeding of feedstocks. Ultimately, it is then possible to obtain abatch of on-spec material, i.e. material displaying the target statewithin acceptable error limits.

The ultimate aim is to take account of the deviations in the propertiesof a continuously manufactured portion of a formulation from theproperties of a predefined target state and to use them to adjust theamounts of feedstocks fed in in the continuous manufacture of furtherportions.

This adjustment is possible in different ways, especially two differentways.

(i) For example, a disproportionate decrease or increase in the massflow of one or more feedstocks compared to the target state is possiblein order ultimately to obtain an on-spec material. This means that anadjustment of amounts of feedstocks fed in overall and/or per unit timeto the process mixer is possible using the deviations between the actualstate of a first portion of a formulation manufactured continuously andthe target state which have been detected by means of the evaluationunit. If an excessively high proportion of a first feedstock has beenused in the context of the manufacture of the first continuouslymanufactured portion, for example, the amount fed in is decreaseddisproportionately compared to the target state in the continuousmanufacture of further material, in order to obtain an on-spec materialoverall. The inverse procedure is correspondingly employed in the caseof excessively low proportions of feedstocks.

(ii) It should be noted, however, that the very small process mixer (kP)compared to the buffer tank means that, in spite of high flow rates, thematerial flow settings for obtaining the target state are generallyobtained before, for example, 5 percent by mass of the batch volumes hasbeen produced. In this case, the adjustment of the mass flow of one ormore feedstocks to the target state can then be made in order ultimatelyto obtain an on-spec material. Thus, production is effected whilekeeping the settings to obtain the target state and the product isdischarged into the buffer tank without conducting a disproportionateadjustment in the mass flows of feedstocks compared to the target state.A batch of on-spec material is then obtained, in which the materialproduced at the start is blended. Even though the target state is notobtained with such exactness as in the case of the adjustment (i) inthis way, the specifications are met.

The adjustment of the mass flows and the configuration of the unit foradjustment of the feeding of feedstocks as electronic control unit arepossible in the manner described for subunit (1.1).

The finished formulations can then be dispensed as described above fromthe buffer tank into disposable or reusable delivery packaging and then,for example, transferred to a warehouse for long-term storage ordelivered directly to a customer.

Preferably, the unit (1) of the production system of the inventionaccordingly comprises a subunit (1.2) for continuous manufacture ofcolored and/or effect-imparting formulations using liquid feedstocksand/or feedstocks which can be used as liquid feedstocks throughpretreatment, comprising

-   -   I. at least one combination of a small-volume process mixer (kP)        and a buffer tank, where the process mixer and the buffer tank        contain mixing devices,    -   II. at least one fluid-conducting connection between the process        mixer and the buffer tank for transfer of a formulation        manufactured continuously in the process mixer from the process        mixer to the buffer tank,    -   III. means of feeding defined amounts of feedstocks into the        process mixer, in this case preferably means for the direct feed        of defined amounts of liquid intermediates from the subunit        (1.1) which were manufactured in the subunit (1.1) being        present,    -   IV. at least one measurement unit for ascertaining properties of        a liquid formulation manufactured continuously in the process        mixer (kP),    -   V. at least one evaluation unit which is in communication with        the measurement unit and is for determination of a deviation in        the properties of a formulation manufactured continuously in the        process mixer (kP) from the properties of a predefined target        state, and    -   VI. at least one unit which is in communication with the        evaluation unit and is for adjusting the feed of feedstocks into        the process mixer (kP), and which is set up to take account of        the deviations in the properties of a continuously manufactured        portion of a formulation from the properties of a predefined        target state and use them to adjust the amounts of feedstocks        fed in in the continuous manufacture of further portions.

It will be apparent from the above that the unit for adjustment of thefeeding of feedstocks, with regard to the actual adjustment, ispreferably adjusted such that, after the manufacture of the overallbatch, this overall batch has the target state (i.e. is on-spec). Whatthis means is that the corresponding correction volumes of feedstocksneeded to establish the target state in the overall batch areascertained in the unit for adjustment, before this then induces acorresponding adjustment in the feeding of feedstocks.

It is of course possible for the production system of the invention andthe unit (1) for production of formulations, as well as the subunit(1.1) and the optionally existing subunit (1.2), also to comprisefurther units and subunits. For example, a subunit (1.3) for productionof intermediates comprising coloring and/or effect-imparting pigmentsand/or fillers (pigment pastes, functional pastes) may exist. It isequally possible for there to be a unit (2) for storage of feedstocks,products and/or empty loading units such as delivery packaging. It isalso possible that a dedicated provision unit (3) for feedstocks exists.It is likewise possible for a pretreatment unit (4) for pretreatment offeedstocks (shaking, stirring and/or tumbling and heating) to bepresent. It is not least possible for a dedicated dispensing unit (5) tobe present.

Process

The present invention also relates to a process for manufacturingformulations. It is self-evidently preferable that the process iseffected using the production system of the invention. It additionallyfollows from the above that preferably paints, for example automotivepaints, are manufactured via the process or via the production system.

Central features and executions of the process have already beendescribed above in the description of the production system. It isadditionally the case that the above-described particular executions andfeatures with regard to the production system are also applicable withregard to the process of the invention. This is especially true inconnection with the preference for liquid feedstocks and feedstocks thatare liquid through pretreatment and for liquid formulations to bemanufactured.

In principle, the process comprises the following steps:

-   -   feeding defined amounts of feedstocks into a process mixer in        which there is a mixing device for dispersion and mixing of        feedstocks,    -   manufacturing a part-batch of a formulation by mixing the        feedstocks in the process mixer,    -   transferring the part-batch into a buffer tank with mixing        device via a connection between process mixer and buffer tank,    -   ascertaining properties of the part-batch before, during or        after transfer into the buffer tank by means of a measurement        unit,    -   determining a deviation of properties of the part-batch from the        properties of a predefined target state by means of an        evaluation unit,    -   ascertaining the correction volumes for feedstocks that are        needed in view of the deviations in the properties of the        part-batch manufactured from the target state and the number and        size of further part-batches for establishment of the target        state of the overall batch,    -   manufacturing at least one further part-batch in the process        mixer, taking account of the correction volumes ascertained in        the manufacture of at least one of the further part-batches by        adjustment of the feeding of feedstocks into the process mixer,    -   transferring the at least one further part-batch into the buffer        tank,    -   combining the at least one further part-batch with the first        part-batch and mixing all part-batches to manufacture the        overall batch.

It is self-evident that the correction volumes in the above sense can beeither positive or negative. A positive correction volume means that ahigher proportion of the particular feedstock has to be used in total inorder to achieve the target state. This can be effected via a higherproportion of the feedstock in the production of at least one furtherpart-batch and/or via smaller proportions of other feedstocks in theproduction of at least one further part-batch. The situation iscorrespondingly reversed with negative correction volumes.

It has been found that the procedure in connection with non-automatedmeasurement of properties in the measurement unit can advantageously beas follows. A total of three part-batches are manufactured, the firstpart-batch and the second part-batch being produced in the same way.During the production of the second part-batch, properties of the firstpart-batch are measured and evaluated with regard to deviations from thetarget state. In addition, the correction volumes are ascertained. Thethird part-batch is then produced taking account of the correctionvolumes. In this way, there remains sufficient time in which thematerial from the first part-batch can be analyzed. Should themeasurement of properties of the first part-batch take longer, theprinciple can of course be extended. In that case, for example, 4part-batches are manufactured, in which case the fourth part-batch isproduced taking account of the correction volumes.

The above-described ascertainment of correction volumes of course meansat the same time that the amounts and ratios in which feedstocks are tobe used for manufacture of formulation material in the target state arelikewise ascertained.

It is therefore possible, after the component steps detailed above haveended, to manufacture further formulation material in the target state.In this case, it is possible to manufacture any desired number offurther part-batches in the process mixer. The part-batches can then betransferred into the buffer tank and, irrespective of the lack of anyneed for combination of the part-batches, can also be dispensed orpassed on to the subunit (1.2).

It is of course possible that, in the process, in a further step, theoverall batch manufactured is dispensed into corresponding deliverypackaging and then, for example, is transferred to a warehouse forlong-term storage or delivered directly to a customer.

This is preferred in the case of the manufacture of products, forexample clearcoats or complete components of paints, for example basevarnish and hardener for a two-component paint. In the case ofmanufacture of intermediates, it is preferable that the process, in afinal step, comprises the transfer of the intermediates to a subunit(1.2) which then exists.

In connection with the subunit (1.2) which is preferably (but notnecessarily) present, the process of the invention preferablyadditionally comprises the steps which follow.

Continuous production of colored and/or effect-imparting formulationswith use of liquid feedstocks and/or feedstocks that can be used asliquid feedstocks through pretreatment, where the production of aformulation comprises the following steps:

-   -   continuously feeding feedstocks into a small-volume process        mixer (kP) in which there is a mixing device for mixing of the        feedstocks,    -   continuously manufacturing a formulation by mixing the        feedstocks in the process mixer (kP) and transferring the        formulation into a buffer tank with a mixing device via a        fluid-conducting connection between the process mixer (kP) and        the buffer tank,    -   ascertaining properties of the continuously manufactured        formulation by means of a measurement unit,    -   determining a deviation of properties of the continuously        manufactured formulation from the properties of a predefined        target state by means of an evaluation unit,    -   ascertaining the adjustment volumes for feedstocks that are        needed in view of the deviations in the properties of the        continuously manufactured formulation from the target state and        optionally the volume of formulation volume to be manufactured        overall for establishment of the target state of the total        volume,    -   continuously manufacturing further volumes of the formulation in        the process mixer, taking account of the adjustment volumes        ascertained by adjusting the feed of feedstocks into the process        mixer.

It is self-evident that the adjustment volumes in the above sense can beeither positive or negative. A positive adjustment volume means that ahigher proportion of the particular feedstock has to be used in total inorder to achieve the target state with the formulation volume to bemanufactured overall. This can be effected via a higher proportion ofthe feedstock in continuous further production and/or via lowerproportions of other feedstocks in continuous further production. Thesituation is correspondingly reversed with negative correction volumes.

Preferably, the continuous feeding of defined amounts of feedstocks intothe process mixer (kP) comprises the direct feeding of intermediateswhich have been manufactured in the subunit (1.1). These feedstocks arethus fed in directly from the subunit (1.1).

It is possible, in the context of the process of the invention, to stopthe continuous manufacture of a formulation by mixing of the feedstocksin the process mixer (kP) and transfer of the formulation into a buffertank with a mixing device via a fluid-conducting connection between theprocess mixer (kP) and buffer tank for a specific period of time. Thisis an option when the measurement and/or evaluation of properties and/ordeviations between the actual state and target state takes acomparatively long time. If the continuous manufacture is then stoppeduntil measurement and evaluation are complete and hence adjustment ofthe feeding of feedstocks into the process mixer is possible, it issubsequently possible to continue production. This is an optionespecially when the plan is to proceed via the above-describedadjustment method (ii).

It is preferable that, in a final step, the overall batch manufacturedis dispensed into corresponding delivery packaging and then, forexample, is transferred to a warehouse for long-term storage ordelivered directly to a customer.

The production system of the invention and the process of the inventionensure that enormously process-efficient and time-saving manufacture offormulations, including an adjustment process, is enabled.

1. A production system for manufacturing of formulations, comprising aunit (1) for the production of formulations, where the unit (1)comprises a subunit (1.1), comprising: a. at least one combination of aprocess mixer and a buffer tank, where the process mixer and the buffertank contain mixing devices; b. at least one connection between theprocess mixer and buffer tank for transfer of part-batches offormulations manufactured in the process mixer from the process mixerinto the buffer tank; c. means (M) of feeding defined amounts offeedstocks into the process mixer; d. at least one measurement unit forascertaining properties of a part-batch of a formulation manufactured inthe process mixer; e. at least one evaluation unit which is incommunication with the measurement unit and is for determination of adeviation of properties of part-batches manufactured in the processmixer from the properties of a predefined target state; and f. at leastone unit which is in communication with the evaluation unit and is foradjusting the feed of defined amounts of feedstocks into the processmixer, and which is set up to take account of the deviations in theproperties of a manufactured part-batch from the properties of apredefined target state and the number and size of further part-batchesin order to adjust the amounts of feedstocks fed in in the manufactureof further part-batches.
 2. The production system as claimed in claim 1,wherein the subunit (1.1) is set up for manufacture of liquidformulations with use of liquid feedstocks and feedstocks that can beused as liquid feedstocks through pretreatment.
 3. The production systemas claimed in claim 2, wherein the subunit (1.1) is set up formanufacture of liquid formulations with exclusive use of liquidfeedstocks and feedstocks that can be used as liquid feedstocks throughpretreatment.
 4. The production system as claimed in claim 1, whereinthe buffer tank has at least 3 times the capacity compared to theprocess mixer.
 5. The production system as claimed in claim 1, whereinthe means (M) have devices for withdrawing defined amounts of feedstocksfrom reservoirs that incorporate technical means of monitoring andclosed-loop control of a mass flow rate of the respective feedstocks. 6.The production system as claimed in claim 5, wherein the means (M)additionally comprise fluid-conducting pipework systems for transfer ofthe defined amounts of feedstocks into the process mixer, the pipeworksystems comprising at least one collecting line.
 7. The productionsystem as claimed in claim 1, wherein the properties that areascertained in the measurement unit include viscosity, pH, conductivity,density and/or temperature.
 8. The production system as claimed in claim1, wherein the unit for adjustment is set up with regard to theadjustment of the feed of feedstocks such that, after the manufacture ofall part-batches (i.e. the overall batch), the overall batch has atarget state predefined by reference values.
 9. The production system asclaimed in claim 1, which additionally comprises a subunit (1.2) forcontinuous manufacture of colored and/or effect-imparting formulationswith use of liquid feedstocks and/or feedstocks that can be used asliquid feedstocks through pretreatment, where the subunit (1.2)comprises: I. at least one combination of a small-volume process mixer(kP) and a buffer tank, where the process mixer and the buffer tankcontain mixing devices; II. at least one fluid-conducting connectionbetween the process mixer and the buffer tank for transfer of aformulation manufactured continuously in the process mixer from theprocess mixer to the buffer tank; III. means of feeding defined amountsof feedstocks into the process mixer; IV. at least one measurement unitfor ascertaining properties of a liquid formulation manufacturedcontinuously in the process mixer (kP); V. at least one evaluation unitwhich is in communication with the measurement unit and is fordetermination of a deviation in the properties of a formulationmanufactured continuously in the process mixer (kP) from the propertiesof a predefined target state; and VI. at least one unit which is incommunication with the evaluation unit and is for adjusting the feed offeedstocks into the process mixer (kP), and which is set up to takeaccount of the deviations in the properties of a continuouslymanufactured portion of a formulation from the properties of apredefined target state and use them to adjust the amounts of feedstocksfed in in the continuous manufacture of further portions.
 10. Theproduction system as claimed in claim 9, wherein the unit (1.1)comprises an onward conduction unit for onward conduction ofmanufactured intermediates to the subunit (1.2).
 11. A process formanufacturing formulations, comprising: feeding defined amounts offeedstocks into a process mixer in which there is a mixing device fordispersion and mixing of feedstocks; manufacturing a part-batch of aformulation by mixing the feedstocks in the process mixer; transferringthe part-batch into a buffer tank with mixing device via a connectionbetween process mixer and buffer tank; ascertaining properties of thepart-batch before, during or after transfer into the buffer tank bymeans of a measurement unit; determining a deviation of properties ofthe part-batch from the properties of a predefined target state by meansof an evaluation unit; ascertaining the correction volumes forfeedstocks that are needed in view of the deviations in the propertiesof the manufactured part-batch from the target state and the number andsize of further part-batches for establishment of the target state ofthe overall batch; manufacturing at least one further part-batch in theprocess mixer, taking account of the correction volumes ascertained inthe manufacture of at least one of the further part-batches byadjustment of the feeding of feedstocks into the process mixer;transferring the at least one further part-batch into the buffer tank;and combining the at least one further part-batch with the firstpart-batch to manufacture the overall batch.
 12. The process as claimedin claim 11, wherein a total of three part-batches are manufactured, byproducing the first part-batch and the second part-batch in the sameway, measuring the properties of the first part-batch and evaluatingthem with regard to deviations, and manufacturing the third part-batchtaking account of the correction volumes ascertained beforehand.